U.S. patent number 5,195,290 [Application Number 07/893,224] was granted by the patent office on 1993-03-23 for laminar roofing product.
This patent grant is currently assigned to American Heartland Roofing Products, Inc.. Invention is credited to John K. Hulett.
United States Patent |
5,195,290 |
Hulett |
March 23, 1993 |
Laminar roofing product
Abstract
A roofing shingle. The shingle includes first, second, and third
substrates. The first substrate includes a woven polyester mat,
treated to make it fire-resistant and to keep it from stretching,
embedded in an asphalt lamina.
Inventors: |
Hulett; John K. (Plymouth,
MN) |
Assignee: |
American Heartland Roofing
Products, Inc. (Plymouth, MN)
|
Family
ID: |
25401233 |
Appl.
No.: |
07/893,224 |
Filed: |
June 3, 1992 |
Current U.S.
Class: |
52/518;
52/DIG.16 |
Current CPC
Class: |
E04D
1/28 (20130101); E04D 1/26 (20130101); E04D
5/10 (20130101); E04D 2001/005 (20130101); Y10S
52/16 (20130101) |
Current International
Class: |
E04D
1/00 (20060101); E04D 1/26 (20060101); E04D
5/00 (20060101); E04D 5/10 (20060101); E04D
001/00 () |
Field of
Search: |
;52/545,315,631,528,521 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Scherbel; David A.
Assistant Examiner: Smith; Creighton
Attorney, Agent or Firm: Nawrocki; Lawrence M.
Claims
What is claimed is:
1. A continuous roll shingle product, comprising:
(a) a first substrate including a woven polyester mat;
(b) a second substrate, overlying and adhered to said first
substrate, including an asphalt material;
(c) a third substrate, overlying and adhered to said second
substrate, including a weather surface; and
(d) an adhesive applied to an undersurface of said first
substrate.
2. A product in accordance with claim 1 further comprising a
release film underlying said adhesive;
wherein, as said product is rolled up, adjacent coils will not
adhere to one another.
3. A product in accordance with claim 1 wherein said weather
surface comprises sand granules embedded in said asphalt
material.
4. A product in accordance with claim 1 wherein said woven
polyester mat is impregnated with a first-retardant agent.
5. A product in accordance with claim 4 wherein said woven
polyester mat is impregnated with a stabilizing agent to retard
stretching of said mat.
6. A product in accordance with claim 1 further comprising a
sealant covering said weather surface.
7. A product in accordance with claim 6 wherein said sealant
comprises a rubber by-product modified asphalt material.
8. A roofing shingle, comprising:
(a) a first substrate including a woven polyester mat;
(b) a second substrate, overlying and adhered to said first
substrate, including an asphalt material;
(c) a third substrate, overlying and adhered to said second
substrate, including a weather surface; said weather surface
comprising particulate granules, made of a ceramic material,
embedded in said asphalt material.
9. A roofing shingle, comprising:
(a) a first substrate including a woven polyester mat;
(b) a second substrate, overlying and adhered to said first
substrate, including an asphalt material;
(c) a third substrate, overlying and adhered to said second
substrate, including a weather surface; and
(d) a sealant covering said weather surface, said sealant
comprising a rubber by-product modified asphalt material.
10. A roofing shingle, comprising:
(a) a first substrate including a woven polyester mat, said woven
polyester mat being impregnated with a fire-retardant agent;
(b) a second substrate, overlying and adhered to said first
substrate, including an asphalt material; and
(c) a third substrate, overlying and adhered to said second
substrate, including a weather surface;
11. A shingle in accordance with claim 10 wherein said woven
polyester mat is impregnated with a stabilizing agent to retard
stretching of said mat.
12. A roofing shingle, comprising:
(a) a first substrate including a woven polyester mat;
(b) a second substrate, overlying and adhered to said first
substrate, including an asphalt material;
(c) a third substrate, overlying and adhered to said second
substrate, including a weather surface; and
(d) a liner applied to an underside of said first substrate to
preclude sticking of one shingle to another when a plurality of
said shingles are enclosed in packaging.
Description
TECHNICAL FIELD
The present invention relates broadly to the field of roofing
coverings. More specifically, however, it is related to a composite
shingle for use, particularly, in the covering of residential
dwelling roofs. -The specific focus of the invention is the
construction of the shingle such that it is more resistant to the
elements and stronger to resist puncture.
BACKGROUND OF THE INVENTION
Numerous shingle products are known in the prior art. Most shingle
products known have a number of goals. First and foremost of these
goals is to preclude the elements from entering into the building
(typically, a residential dwelling) with which the shingle is used.
In furtherance of this objective, shingle manufacturers seek to
make their products so they are resistant to hail, wind, and other
aspects of the elements which might tend to deteriorate their
products over the passage of time.
Another goal of shingle products is resistance to fire. The typical
application for shingle products is in use in residential
dwellings. Consequently, safety is an important consideration in
the construction of a shingle product. It is desirable that a
shingle be retardant to fire not only so that it does not, itself,
burn, but also that it retards the spread of fire within the
structure.
A third goal of all shingle products is that they be easy to apply.
Included in this objective are the desires that the product be easy
to handle, easy to position, and easy to mount.
The capstone goal of a shingle product is that it be aesthetically
pleasing. Because of the particular application of shingle products
in the residential dwelling market, purchasers frequently look to
the aesthetics of the product in ultimately deciding on a
particular product they wish to use.
It is to these dictates and problems of the prior art that the
present invention is directed. It is an improved roofing shingle
product which serves to solve numerous problems of the prior art
without sacrificing desirable characteristics already afforded by
prior art structures.
SUMMARY OF THE INVENTION
The present invention is a roofing shingle which includes a
plurality of substrates. A first substrate includes a foundational
lamina which has a woven polyester mat to give the overall product
form and strength. A second substrate which, typically, comprises
an asphalt material, overlies, and is adhered to, the first
substrate. Finally, a third substrate overlies, and is adhered to
the second substrate. The third substrate comprises a treated
weather surface which not only serves a protective function, but
also makes the shingle aesthetically pleasing.
In a preferred embodiment of the invention, the woven polyester mat
is chemically treated. One chemical treatment includes impregnating
the mat with a fire retardant material. Such a treatment would
render the polyester mat, frequently in Class C on the scale of
fire retardency, in Class A, the highest level on the scale.
The preferred embodiment also contemplates impregnation of the
woven polyester mat with a stabilizer material. Such material
effects resistance to stretching of the mat. As a result, the
overall shingle product is afforded with a uniform, stable size and
shape.
It is envisioned that the polyester mat would be embedded in a
lamina of asphalt material. The woven polyester mat and the lamina
of asphalt material in which it is embedded, therefore, together
comprise the first substrate of the composite shingle in accordance
with the present invention.
The second substrate, typically, comprises a layer of asphalt,
overlying the first substrate. The third substrate weather surface
can comprise particulate mineral granules. These granules can be
ceramic in nature, and can be embedded on the second substrate
asphalt material medium.
If desired, a sealant can be applied over the weather surface of
the shingle. That is, a sealant can be applied over the ceramic
mineral granule third substrate. Such a sealant is, typically,
adhesive in nature, and can take the form of a modified
asphalt.
In order to facilitate the provision of a new roof to a residential
dwelling, for example, the undersurface of each composite shingle
constructed as described can be provided with a liner release
sheet. Consequently, when a plurality of the composite shingles are
packaged together with one overlying the next, each individual unit
can be easily separated from the others.
To facilitate mounting of the composite shingles to a roof surface,
indicia can be provided to represent locations at which nails are
to be pounded through the shingle. Such indicia can comprise spots,
at appropriate locations on the weather surface of the shingle,
representative of intended nail locations.
The present invention is thus an improved composite shingle product
which solves many of the problems of the prior art. More specific
features and advantages obtained in view of those features will
become apparent with reference to the DETAILED DESCRIPTION OF THE
INVENTION, appended claims, and accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a first substrate of the shingle
showing an asphalt lamina and a woven polyester mat;
FIG. 2 is a sectional view, similar to FIG. 1, showing the
polyester mat embedded in the asphalt lamina;
FIG. 3 is a sectional view similar to FIGS. 1 and 2 showing second
and third substrates formed integrally with the first
substrate;
FIG. 4 is a top plan view of a specific configuration of a shingle
made in accordance with the present invention;
FIG. 5 is a sectional view taken generally along line 5--5 of FIG.
4, an adhesive and liner being illustrated;
FIG. 6 is a top plan view, similar to FIG. 4, showing a second
shingle product;
FIG. 7 is a sectional view taken generally along line 7--7 of FIG.
6;
FIG. 8 is a top plan view, similar to FIG. 6, showing another
shingle product;
FIG. 9 is a top plan view showing another shingle product;
FIG. 10 is a sectional view taken generally along line 10--10 of
FIG. 9;
FIG. 11 is a top plan view, similar to FIG. 9, showing another
shingle product employing the present invention;
FIG. 12 is a top plan view showing a configuration of a roofing
roll alternative embodiment;
FIG. 13 is a sectional view taken generally along line 13--13 of
FIG. 12;
FIG. 14 is a top plan view showing a further alternative
configuration of a roofing roll;
FIG. 15 is a top plan view showing another alternative
configuration of a roofing roll;
FIG. 16 is a fragmentary perspective view showing a cap shingle
embodiment illustrated on a roof peak;
FIG. 17 is a top plan view thereof;
FIG. 18 is a perspective view showing a cap selection alternative
embodiment; and
FIG. 19 is a fragmentary perspective view thereof shown on a roof
peak.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like reference numerals
denote like elements throughout the several views, FIGS. 1 and 2
illustrate a first substrate 20 of a composite roofing shingle
product in accordance with the present invention. FIG. 1
illustrates that substrate 20 with a woven polyester mat 22
separated from an asphalt material carrier lamina 24 in which the
polyester mat 22 can be embedded. FIG. 2 illustrates a first
substrate 20 with the polyester mat 22 already embedded in the
asphalt material lamina 24. It will be understood that the mat can
be embedded in the lamina 24 in any appropriate manner and that the
specific manner in which the lamina 24 receives the polyester mat
22 is not part of the invention.
The polyester mat 22 utilized is of a type known, in isolation, in
the art. A number of appropriate woven mat materials are made by
Hoechst Celanese Corporation. These include a number of fabrics
identified as Trevira Spunbond Polyester Mat Base Type 32
including, specifically, fabrics 3214, 3218, and 3225. These
specific fabrics provide adequate strength in multiple directions
and resistance to tearing and puncture in order to accomplish the
objectives intended to be achieved by a composite roofing shingle
structure in accordance with the present invention. FIG. 3
illustrates a second substrate 26 overlying, and adhered to, the
first substrate 20, and, further, a third substrate 28 overlying,
and adhered to the second substrate 26. The three substrates 20,
26, 28 are thus bonded together to form a unitary construction.
The second substrate 26 is a coating which immediately overlies the
base or mat substrate 20. The coating, typically, comprises an
asphalt material similar to the lamina material which the first
substrate 20 includes. It will be understood by one of skill in the
art that these two laminae 20, 26 can be easily bonded together by
applying heat and/or pressure to effectively meld the laminae
together.
The third substrate 28, as previously discussed, overlies, and is
adhered to, the second substrate 26. The third substrate 28
comprises a weather surface which, when the shingle product in
accordance with the present invention is mounted to the roof of a
building (for example, a residential dwelling), is exposed to the
elements. Typically, the third substrate 28 comprises particulate
granules 30 which are embedded in the asphalt material of the
second substrate 26. In a preferred embodiment, the particulate
granules 30 which would be employed would be mineral granules of a
ceramic material.
If appropriate and desired, a sealant material can be employed to
cover the weather surface (that is, the particulate ceramic
material granules) of the third substrate 28. In the preferred
embodiment, the sealant takes the form of a modified asphalt which
has a rubber by-product mixed therein. Potential suppliers of such
a sealant are Sika Corporation and Shell Chemical Company.
As discussed in this document, it is optimum for the woven
polyester mat 22 and, in fact, all components of the composite
shingle product) to be fire retardant in nature. Since polyester
fiber mats as discussed hereinbefore tend to have a Class C rating
when they are untreated, treatment can be accomplished by
employment of a fire retardant agent to impregnate the mat. An
appropriate dry chemical fire retardant agent is manufactured by
the 3M Corporation of St. Paul, Minnesota and the Shell Chemical
Company of Houston, Texas. By impregnating the polyester mat with
such an agent, the mat can achieve a Class A rating. Safety
standards can, thereby, be achieved.
As previously discussed, woven polyester mats as indicated have
high resistance to puncture and tears. In an untreated state,
however, they can be subject to deformation because of fiber
shiftings. It can be desirable, therefore, to treat the mat 22 with
a stabilizing agent. Such an agent can effect bonding of the fibers
so that fiber shifts will be inhibited and a more stable and
uniformly sized and shaped mat (and, consequently, a composite
shingle product employing the mat) can be provided. Any appropriate
stabilizing agent known in the prior art can be employed to
accomplish this goal.
As previously discussed, the asphalt material employed in both the
first and second substrates 20, 26 can be the same medium. A
particular asphalt material that has been found acceptable for use
in the present invention is one containing Kraton G (SEBS)
Copolymers. Such a product is manufactured by Shell Chemical
Company.
FIGS. 4 and 5 illustrate a particular shingle product 32
manufactured employing the three-substrate construction in
accordance with the present invention. The particular product 32
illustrated is shown as having a plurality of roofing location
slits 34 as known in the prior art. A number of tab portions 36
extend downwardly and simulate separate shingles. FIG. 4
illustrates indicia 38, located on the weather surface of the
shingle product 32, to identify locations at which nails are to be
pounded through the shingle 32 to mount the shingle to a roof. It
will be understood that these indicia 38 could be provided in any
appropriate manner. Spots could be colored onto the weather
surface, or indentations could be provided in that surface.
FIG. 5 illustrates employment of a liner 40 applied to a tacky
underside 42 of the first substrate 20. Such a liner 40 can
function to insulate one shingle unit 32 from immediately adjacent
shingle units in the same package. Individual shingles are,
thereby, more accessible to the installer. It will be understood
that this liner 40 need not be removed prior to installation of the
shingle unit, although removal could be accomplished if
desired.
FIGS. 6 and 8 illustrate two-ply shingle products 44, 46. If
desired for aesthetic reasons, a bottom ply 48, 50 can employ
darker colored mineral granules to lend contrast to the product. A
more appealing appearance is, thereby, provided.
FIG. 7 shows a cross-section of the product illustrated in FIG. 6.
As can be seen in FIG. 7, each ply has a construction substantially
the same as the cross-sectional construction of the product
illustrated in FIG. 4. That is, each ply has a three-substrate
laminar structure.
FIGS. 9 and 11 illustrate three-ply shingle products 52, 54. FIG.
10 illustrates a typical cross-section of those products. As can be
seen, each ply is provided with a three-substrate configuration,
that configuration being the same as those for the shingle products
illustrated in FIGS. 4, 6, and 8. The plies are bonded together in
an appropriate manner.
FIGS. 12, 14, and 15 illustrate three special applications of
roofing roll embodiments 56, 58, 60. FIG. 13 illustrates an
enlarged cross-sectional portrayal of the embodiment of FIG. 12. As
will be seen with reference to FIG. 13, the cross-section of the
embodiment of FIG. 12 is substantially the same as the
cross-sections of embodiments previously described herein. FIG. 13,
however, shows an adhesive 62 as specifically being provided on an
underside of the first substrate. Such an adhesive 62 enables quick
and facile positioning of a length of the material, as shown in
FIG. 12, from a roll.
FIG. 13 also illustrates a release film 64 as overlying the
adhesive layer 62 The product 56 illustrated in FIG. 12 being
provided in a roll configuration, a coil of the product in
engagement with a immediately adjacent coil could become adhered to
that coil if the release film were not provided. Prior to
application for the intended purpose, the release film 64 merely
need be withdrawn from the adhesive 62 in order to expose the
adhesive 62 for application.
It will be understood that the cross-sections of the embodiments of
FIGS. 14 and 15 are substantially the same as that of the
embodiment of FIG. 12. The embodiments of FIGS. 14 and 15 are also
intended to have an adhesive and an overlying release film.
The third substrate (that is, the weather surface) varies depending
upon the specific application of the embodiment. For example, one
embodiment (the one illustrated in FIG. 12) would have sand
granules embedded in the asphalt material of the second substrate.
Such an embodiment would, typically, be used where no part of the
weather surface were intended to be exposed to view.
The embodiments of FIGS. 14 and 15 have some portion of the weather
surface formed by the embedding of ceramic mineral granules in the
asphalt material of the second substrate. Other portions, however,
employ sand embedded in the asphalt material of the second
substrate.
It is intended that exposed areas would be covered with ceramic
mineral granules, while non-exposed areas would be covered by sand
granules. The embodiment illustrated in FIG. 14 has sand granules
extending along the lateral portions of the roll material and
ceramic mineral granules extending along the medial portion of the
roll material. FIG. 15 shows a roll material construction wherein
sand is embedded in the asphalt material along much of the weather
surface, only a small marginal portion at the lower edge of the
roll, as at 66, having ceramic mineral granules embedded
therein.
FIGS. 17 and 16, respectively, illustrate an embodiment of a
roofing shingle 67 having the laminar structure as previously
discussed, and a roof peak ventilation system area 68 to which such
shingles are to be applied. As seen in FIG. 17, a generally
rectangular portion 70 of the shingle product 67 illustrated
therein has a third substrate that is formed by embedding ceramic
mineral granules in the second substrate asphalt material. A
trapezoidal portion 72 of the product 67, however, has no granular
materials whatsoever. Rather, the trapezoidal portion 72 is
intended to effect adherence of the product 67 to the substructure
to which it is to be attached to facilitate the securing of an
overlapping product unit in an attached relationship. It will be
understood that only the rectangular portion 70 of the ceramic
mineral granules embedded therein would be exposed to view once the
product 67 is in place.
FIGS. 18 and 19, respectively, show another embodiment of a roofing
shingle product 74 in accordance with the present invention and its
manner of application at a cap section 76 of a roof 78. The product
is shown as having a third substrate which is completely embedded
with ceramic mineral granules. Substantially the full upper surface
of the product is exposed to view. A small segment of one unit,
however, overlaps with a small portion of the immediately adjacent
segment. The units which are, thereby, aligned extend the crest of
the roof and straddle the crest with approximately half of the
width of the each unit on either side of the crest.
As best seen in FIG. 18, the underside of the first substrate of
the product illustrated therein is provided with an adhesive 80,
and such an adhesive 80 facilitates maintenance of the product unit
in the intended position. A peel-off release film 82 is shown as
normally being in place overlying the adhesive 80 so as to protect
the tacky surface 84. Again, the release film 82 can be withdrawn
immediately prior to application.
As in the case of the roll products illustrated in FIGS. 12, 14,
and 15, the cross-sections of the products illustrated in FIGS. 17
and 18 are substantially the same as the cross-sections of the
other products disclosed herein. They therefore are afforded with
the laudatory advantages of being provided with a first substrate
having a woven polyester mat therein.
Numerous characteristics and advantages of the invention covered by
this document have been set forth in the foregoing description. It
will be understood, however, that this disclosure is, in many
respects, only illustrative. Changes may be made in details,
particularly in matters of shape, size, and arrangement of parts
without exceeding the scope of the invention. The invention's scope
is, of course, defined in the language in which the appended claims
are expressed.
* * * * *